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ABSTRACT
In material handling, the cranes play a vital role in modern manufacturing industries. In our
project we aim to fabricate a hydraulic operated floor crane for handling various kinds of
materials. The hydraulic floor crane consists of truck, hydraulic cylinder, hydraulic tank,
hydraulic hoses, DCV, beam and hooks. The beam one end is fixed to the truck and another
end is attached to the hooks. The hydraulic cylinder is connected to the horizontal arm. The
hydraulic tank is pumping to the hose in upward direction. At the same time material is lifted
with the help of hook and hydraulic cylinder released to the pressure valve so the material is
unloaded. The material from one place goes to the other place with the help of hydraulic floor
crane. The crane reduces the workers fatigue and increases the overall efficiency of
production processes with good safety. The crane is fabricated with complete clear front,
small compact frame, good reach, high lift and with low center of gravity. The crane has the
capacity of lifting 10 kg with wide spread application in the shop floor. Thus the floor crane
would serve as a safe and versatile model for material handling operations.
1.1 Introduction
A crane is a type of machine, generally equipped with a hoist, wire ropes or chains,
and sheaves, that can be used both to lift and lower materials and to move them horizontally. It
is mainly used for lifting heavy things and transporting them to other places. It uses one or
more simple machines to createmechanical advantage and thus move loads beyond the normal
capability of a man. Cranes are commonly employed in the transport industry for the loading and
unloading of freight, in the construction industry for the movement of materials and in the
manufacturing industry for the assembling of heavy equipment.In material handling, the cranes
play a vital role in modern manufacturing industries. Hydraulic cranes are heavy equipment used
primarily for lifting.These Hydraulic floor Cranes, provide an efficient low cost alternative to
other material handling equipment. Strong, robust, study and built to very standard. Laden, these
cranes are manoeuvrable and loading, unloading and shifting of heavy load. Crane structure
consists of chasis, verticalcolumn, inner boom and outer boom, and thehydraulic pump with
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cylinder assembly. The boxframe can take heavy loads effectively, avoidsand damage under
rough and unskilled handling.Inner and outer boom is suitably reinefoast the bow structure for
better distribution of force. Innerboom has 3 locking points telescopes into theouter boom with
360 rotating forged steel hook.
2.1 DESIGN WORK:
The designing work was carried out using CATIA software. The required dimensions
of the driver and the driven wheels were taken as per the design equations. CATIA is the
most widely used design softwares which helps in designing 2 as well as 3 dimensional
models using simplified alphabetical and numerical commands. Both the driving and the
driven wheels were drawn to the required dimensions using the circle command. A slot was
cut on the Geneva wheel using the trim tool. It was then edited using polyline command and
the remaining slots were constructed using the array tool. The crank pin and the driving
wheel were drawn to the required dimensions
2.2 DESIGN CRITERIA:There are three major considerations in the design of cranes.
2.2.1 The crane must be able to lift the weight of the load;
2.2.2 The crane must not topple;
2.2.3The crane must not rupture.
1. The lever:A balance crane contains a horizontal beam (the lever) pivoted about a point called
the fulcrum. The principle of the lever allows a heavy load attached to the shorter end of the
beam to be lifted by a smaller force applied in the opposite direction to the longer end of the
beam. The ratio of the loads weight to the applied force is equal to the ratio of the lengths of
the longer arm and the shorter arm, and is called themechanical advantage.
2. The pulley:A jib crane contains a tilted strut (the jib) that supports a fixed pulley block. Cables are
wrapped multiple times round the fixed block and round another block attached to the load.
When the free end of the cable is pulled by hand or by a winding machine, the pulley system
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delivers a force to the load that is equal to the applied force multiplied by the number of
lengths of cable passing between the two blocks. This number is the mechanical advantage.
This can be used directly to lift the load or indirectly to move the jib or beam that carries
another lifting device.Cranes, like all machines, obey the principle of conservation of energy.
This means that the energy delivered to the load cannot exceed the energy put into the
machine. For example, if a pulley system multiplies the applied force by ten, then the load
moves only one tenth as far as the applied force. Since energy is proportional to force
multiplied by distance, the output energy is kept roughly equal to the input energy (in practice
slightly less, because some energy is lost to friction and other inefficiencies).
The same principle can operate in reverse. In case of some problem, the combination of
heavy load and great height can accelerate small objects to tremendous speed. Such
projectiles can result in severe damage to nearby structures and people. Cranes can also get in
chain reactions; the rupture of one crane may in turn take out nearby cranes. Cranes need to
be watched carefully.
Stability:For stability, the sum of all moments about any point such as the base of the crane must
equate to zero. In practice, the magnitude of load that is permitted to be lifted (called the
rated load in the US) is some value less than the load that will cause the crane to tip
(providing a safety margin).
Standards for cranes mounted on ships or offshore platforms are somewhat stricter because of
the dynamic load on the crane due to vessel motion. Additionally, the stability of the vessel or
platform must be considered.
For stationary pedestal or kingpost mounted cranes, the moment created by the boom, jib, and
load is resisted by the pedestal base or kingpost. Stress within the base must be less than the
yield stress of the material or the crane will fail.
MANUFACTURING PROCESS
3.1 Manufacturing:The hydraulic crane which was manufactured has 12 parts. They are Base plate/
Truck/Pallet, Hydraulic tank, Hydraulic hoses,Direction control valve, Vertical
column, Ball bearings, Horizontal arm, Secondary horizontal arm, Hydraulic cylinder,
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Roller, Hook, Nuts and Bolts,Wheels. Base platesare made of caste iron metal rod.
The rodsare cut according to the dimensions and they are welded using metal arc
welding.Then bearing was selected according to the thrust and axial load and vertical
column are fitted on the bearing so that it can rotate to a 360.The fixed horizontal
arm is welded. And secondary horizontal arm was fixed with hook. Hydraulic system
are selected according to the power required and capacity of tank.
3.2Machining process:3.2.1
3.2.2
3.2.3
3.2.4
Surface finishing
Metal cutting
Surface grinding
Welding
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Metal cutting is basically done to get the right dimensions and size as per the required
design, using machines that have single point cutting tool or multi-point cutting tool.
Initially the dimensions are marked and then the metal cutting operation is done.
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3.2.4 GRINDING:
Grinding is done on the edges for getting the smooth finish, the grinding machine removes
the material from the metal surface in the form of sparks as shown in the figure
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3.3 ASSEMBLING :
The assembly of the various parts and structure of our project is done using nuts and
bolts, welded fixtures, fasteners, etc.
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MATERIAL SELECTION
Mo
MOLYBDENU
M
-
4.3SELECTION OF WHEELS:
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DESIGN CALAULATIONS
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Length of truck=65cm=0.65m
Breadth of truck=45cm=0.45m
Height of vertical column=100cm=1m
1. Calculation of floor load :Floor load is a measure of pressure on the floor of truck. It is
necessary to avoid the catastrophic failure.
Total weight= 20kg
Length= 65cm= 0.65m
Breadth= 45cm= 0.45m
Floor load= total weight/total floor area
= W/(l*b)
=20/ (0.65*0.45)
= 68.37kg/m2 or 68.37 N
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2. Flow
= [motor speed(rev/min)*pump displacement(cc/rev)]/1000
=1420*1.76/1000
=2.1cc/min
3. Shaft torque
= [pump displacement(cc/min)*pressure(bar)]/[20*P*I*3.142]
=[1.73*350]/[20*920*3.142]
=53N-m
4. Power out
=[speed(rev/min)*pump displacement(cc/min)*pressure(bar)*100]/600
=[1420*1.73*350*100]/600
=830watt
5.Fluid velocity in hose
Continuity equation:-
Q= AV
Q = *(d2/4)*V
V=[(Q*4)/(*d2)]
=[(2.5*4)/(899**0.01 2)]
= 35.40 m/s
(Density of fluid at room temperature = = 899 kg/m3)
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F
F
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ASSEMBLY DIAGRAM
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CHAPTER: 8
SNAP SHOTS
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CONCLUSION
The aim of our project was to build a fully functional HYDRAULIC FLOOR CRANE
mechanism which is capable of lifting load up to 10 kg . We accurately achieved our first
goal of lifting the load and 360 rotary motion of the vertical column .
We feel that our design and fabrication was a great success both in terms of strength and
stiffness. Our project weighed 10kg which is capable of lifting load up to 10kg using
hydraulic power.
REFERENCES
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